Warrior Products 30841 Installation guide

Brand
Warrior Products
Model
30841
Type
Installation guide

This manual is also suitable for

INSTRUCTION SHEET
Page 1
#30741 4” ECONOMY LIFT KIT – JEEP TJ
Warrior recommends this system be installed by a certified technician. In
addition to these instructions, professional knowledge of
disassemble/reassembly procedures as well as post installation checks must
be known. Attempts to install this system without this knowledge and
expertise may jeopardize the integrity and/or operating safety of the vehicle.
Please read instructions before beginning installation. Check the kit
hardware against the parts layout and list found on the last page of these
instructions. Be sure you have all needed parts and know where they go.
With the installation of all lift kits and larger tires it is important to check
the condition of your steering stabilizer. If the stabilizer is worn or is
leaking it should be replaced. Steering stabilizers are designed to restrain
“bump steering” and front end vibration, giving added life to tires, ball
joints, and other steering components. A multiple stabilizer kit is
recommended for vehicles equipped with a winch or larger tires
PRODUCT USE INFORMATION
1. As a general rule, the taller a vehicle is, the easier it will roll. Offset, as much as possible, what is lost in rollover resistance by
increasing tire track width. In other words, go "wide" as you go "tall". Many sportsmen remove their mud tires after hunting
season and install ones more appropriate for street driving; always use as wide a tire and wheel combination as possible to
enhance vehicle stability.
2. We strongly recommend, because of rollover possibility, that the vehicle be equipped with a functional roll-bar and cage
system. Seat belts and shoulder harnesses should be worn at all times. Avoid situations where a side rollover may occur
3. Generally, braking performance and capability are decreased when significantly larger/heavier tires and wheels are used. Take
this into consideration while driving.
4. Do not add, alter, or fabricate any factory or after-market parts to increase vehicle height over the intended height of the
Warrior product purchased. Mixing component brands is not recommended.
5. Warrior makes no claims regarding lifting devices and excludes any and all implied claims. We will not be responsible for any
product that is altered.
6. The required installation time for this system is approximately 8 hours.
7. This suspension system was developed using a 33 x 12.50R – 15 tire, on a 8” wheel. Before installing other combinations,
please consult your local tire and wheel specialist.
8. The following tools and supplies are recommended for proper installation of this kit.
a. Spring Compressor b. Pitman Arm Puller
c. Silicone Spray d. Drill Motor
e. Drill Assortment (1/8” to 1/2") f. Torque Wrench (250 ft lbs. Capacity)
g. Hammer h. ½” Drive Ratchet and Sockets
i. Combination Wrenches j. Allen Wrenches
k. Torx Key Socket l. Hacksaw
m. File n. Large “C” Clamps and/or Bench Vise
o. Hydraulic Floor Jacks p. Heavy Duty Jack Stands
q. Wheel Chocks (Wooden Blocks) r. Molybdenum Grease or Anti Seize Compound
s. Safety Glasses – Wear safety glasses at all times
If question exist we will be happy to answer any questions concerning the design, function, and correct use of our products.
FIGURE 1
INSTRUCTION SHEET
Technical Assistance - (888) 220-6861 Page 2
STANDARD BOLT TORQUE SPECIFICATIONS
INCH SYSTEM METRIC SYSTEM
Bolt
Size Grade 5 Grade 8 Bolt Size Class 9.8 Class 10.9 Class 12.9
5/16 15 Ft – Lbs 20 Ft – Lbs M 6 5 Ft – Lbs 9 Ft – Lbs 12 Ft – Lbs
3/8 30 Ft – Lbs 35 Ft – Lbs M 8 18 Ft – Lbs 23 Ft – Lbs 27 Ft – Lbs
7/16 45 Ft – Lbs 60 Ft – Lbs M10 32 Ft – Lbs 45 Ft – Lbs 50 Ft – Lbs
½ 65 Ft – Lbs 90 Ft – Lbs M12 55 Ft – Lbs 75 Ft – Lbs 90 Ft – Lbs
9/16 95 Ft – Lbs 130 Ft – Lbs M14 85 Ft – Lbs 120 Ft – Lbs 145 Ft – Lbs
5/8 135 Ft – Lbs 175 Ft – Lbs M16 130 Ft – Lbs 165 Ft – Lbs 210 Ft – Lbs
¾ 185 Ft – Lbs 280 Ft – Lbs M18 170 Ft – Lbs 240 Ft – Lbs 290 Ft – Lbs
NOTICE TO DEALER AND VEHICLE OWNER
Any vehicle equipped with any Warrior product should have a “Warning to Driver” decal installed on the inside of the windshield
or on the vehicle’s dash. The decal should act as a constant reminder for whoever is operating the vehicle of its unique handling
characteristics.
INSTALLING DEALER - it is your responsibility to install the warning decal and forward these installation instructions on to the
vehicle owner for review. These instructions should be kept in the vehicle for its service
INSTALLATION INSTRUCTIONS
1. The front-end components are installed first.
2. Place the vehicle on a level surface. Set the parking brake. Center front wheels and chock rear wheels. From inside the engine
compartment, remove the upper stud nut, retainer and grommet form both of the front shocks Jack up the vehicle and place
jack stands on the frame rail behind the lower control arm mount on the frame. Installation is done one end at a time.
3. Remove the front tires and wheels.
4. Place a floor jack underneath the axle for support and complete the removal of the front shock absorbers (DO NOT REUSE
THE ORIGINAL SHOCK ABSORBERS).
5. Remove the track rod from the axle housing and secure out of the way. Save the bolt and flag nut they will be reused in a later
step. Remove both of the front sway bar end links.
6. Remove the brake calipers and secure out of the way.
7. Mark the position of the lower control arm cam bolt and axle brackets for installation reference. (See Figure #1) If equipped
with ABS brakes, Remove the sensor wires and clamps for the inside of the lower arms and save clamps for re-use.
8. Remove the coil spring clip located on the bottom coil seat on both sides of the vehicle. Lower the axle and remove the coil
spring. A coil spring or strut compressor may be needed to remove the stock coil spring.
9. Install the coil spring. A coil spring or strut compressor will be needed for the new coil spring installation. Compress the
new coil spring to 16” in length. Install the new spring into the upper and lower spring pockets and carefully remove the
compressor. Make sure the coil is seated properly in the coil seat by rotating the spring so the pig tail end fits in the spring
pocket. Install the coil spring clamp and torque the spring clip bolt to 16ft.-lbs.
10. Repeat steps on other side.
11. Assemble the boots on the front shock absorbers, part #60506 and install in the factory lower mounts. Install the upper stud
bushings and tighten the upper mounting point. Tighten the bar pin on the bottom of the shock with the stock hardware.
Repeat this on the opposite side of the vehicle. Install the tires, wheels and lug nuts. Lower the vehicle to the ground.
12. Align the reference marks on the adjustment cams and lower arm axle brackets and tighten to 85 ft. lbs.
Note: Longer brake lines are not required in the front with this kit unless the sway bar is disconnected. If disconnects are used,
longer brake lines are required. Install tires and wheels.
13. Chock the front wheels. Jack up the rear of the vehicle and remove the tires and wheels. Place jack stands on the frame rail
to support the vehicle. Place a floor jack under the differential. Remove the stock shock absorbers and sway bar links. Retain
the factory shock hardware it will be reused.
14. On the rear of the vehicle unbolt the track rod from the axle and secure out of the way.
15. Carefully lower the axle with the floor jack and remove the coil springs. NOTE: It may be necessary to use a coil spring or
strut compressor to remove the stock coil springs. Be careful not to overextend the vent tube on the axle. It may be
necessary to disconnect the hose during installation and reroute the hose after installation.
16. Install the new Warrior coil springs making sure that the rubber damper is positioned in the upper mount. It will be necessary
to use a coil spring or strut compressor to install the new coil springs. Jack up the axle to compress the coil spring and to align
the track rod with the new mounting point and install the stock mounting hardware.
17. Assemble shock # 60507 with the shock bushings and sleeves in the shock bag on the larger barrel end. Install the shocks on
the vehicle with the factory hardware.
INSTRUCTION SHEET
Technical Assistance - (888) 220-6861 Page 3
18. Reinstall the wheels, tires. Lower the vehicle to the ground and tighten the lug nuts to the factory torque specifications (80-
110 ft-lbs.)
19. Tighten lower arm pivot bolts to 130 ft. lbs and the track bar mounting bolts to 74 ft. lbs.
20. A brake line bracket is supplied with this kit for the rear of the vehicle. Remove the brake line at the frame mount. Do not
remove the rubber line from the steel line. This will cause the brakes not to function properly unless the lines are bled. Mount
the bracket to the factory location with the supplied hardware and tighten. Place the factory line at the other end of the bracket
in the slotted hole.
21. To install the transfer case, place the transmission in neutral and place a floor jack under the transmission mount skid plate to
support it.
22. Slightly loosen the bolts on the transfer case skid plate on both sides to allow for some movement. Do not remove the bolts.
23. Proceed to other side. NOTE: Do not attempt to take out the bolts on both sides simultaneously. Installation is done one side
at a time. Remove the three bolts holding the transfer case skid plate to the frame rail.
24. Using the floor jack, slightly lower the skid plate and insert the six transfer case spacers.
25. Using the bolts and conical washers supplied with the kit slightly tighten the bolts. Do not fully tighten to allow for some
movement for the opposite side. Conical end of the washer must fit over the mounting hole in the cross-member.
26. After installing both sides, tighten bolts to 45ft lbs.
27. Center the steering wheel and mark the position of the original pitman arm. Remove the nut and washer from the steering
gear box.
28. Remove the pitman arm from the steering gear with a pitman arm puller.
29. Align and install new pitman arm on the steering gear shaft. Install the washer and nut. Tighten to 185 ft. lbs.
30. Install the drag link ball stud to the pitman arm. Install the nut and tighten to 60 ft lbs. Install a new cotter pin.
POST INSTALLATION INSTRUCTIONS
1. Check all fasteners for proper torque. Check to ensure there is adequate clearance between all rotating, mobile, fixed and
heated members. Check steering gear for interference and proper working order. Test brake system.
2. Readjust headlamps. Have the vehicle aligned to the following specifications:
Adjustment Preferred Range
Caster 7° ± 1°
Camber - 0.25° ± .63°
Toe In (each wheel) 0.15° ± .15°
Thrust Angle 0° ± .15°
3. Perform steering sweep. Check to ensure brake hoses have sufficient slack and will not contact rotating, mobile, or fixed
members, adjust lines/brackets to eliminate interference and maintain proper working order. Failure to perform inspections
may result in component failure.
4. Re torque all fasteners after 500 miles. Visually inspect components and re torque fasteners during routine vehicle service.
MAINTENANCE INFORMATION
It is the ultimate buyers responsibility to have all bolts/nuts checked for tightness after the first 100 miles and then every
1000 miles. Wheel alignment, steering system, suspension and driveline systems must be inspected by a qualified professional
mechanic at least every 3000 miles. PARTS LIST
FRONT COIL SPRINGS TRANSFER CASE SPACER
KIT FRONT SHOCK Black Shock Boots (4)
800001 800029 60506 (2) Boot Ties (4)
Installation Instructions
REAR COIL SPRINGS REAR SHOCK TJ Shifter Linkage Brkt
800002 60507 (2)
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Warrior Products 30841 Installation guide

Brand
Warrior Products
Model
30841
Type
Installation guide
This manual is also suitable for
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